Absorbent stretchable fabric

ABSTRACT

An absorbent fabric, preferably used as a diaper, comprised of an absorbent shrinkable web encased in a warp knitted fabric of relatively non-shrinkable yarn. The fabric is substantially nonstretchable when made, but becomes stretchable after washing and drying. A method of making a stretchable fabric is also disclosed.

Hunted States Patent 1 1 1111 3,717,151)

Schwartz 51 Feb. 20, 1973 [54] ABSORBENT STRETCHABLE FABRIC 2,774,12712/1956 Secrist .,l61/75 x 3,388,028 6/1968 Alexander ..161/156 [75]lnventor. Samuel M. Schwartz, El Paso, Tex. 3386,44] 6/1968 De Merrem61/156 X [73] Assignee: Farah Manufacturing Company, 2,768,420 10/1956Rumofl l/75 X [m E] p Tu 3,405,674 10/1968 CoatesetaL. ....l6l/82X3,339,549 9/1967 Morse ..66/192 x [22] Filed: Sept. 9,1970

Primary ExaminerWilliam A. Powell 1. N 7 [211 App 0 0,650 AssistantExaminer-James J. Bell Att0rneyBrumbaugh, Graves, Donohue & Raymond [52]U.S. C1. ..128/284, 66/192, 161/50,

161/86, 161/88, 161/149, lf6l/l/56 [57] ABSTRACT [51] lnt.Cl. ..A61 1316 [58] Field of Search ...128/284, 287; 66/192; 161150 An absorbentfabnc, preferably used as a d1aper, coml6ll86 88 149 156 prised of anabsorbent shrinkable web encased in a warp knitted fabric of relativelynon-shrinkable yarn. [56] References Cited The fabric is substantiallynon-stretchable when made, but becomes stretchable after washing anddrying. A UNITED STATES PATENTS method of making a stretchable fabric isalso dis- 3,457,738 7/1969 Book etal. ..66/192 closed 174,199 2/1876Cohn. ..161/86 16 Claims, 8 Drawing Figures 3,382,072 5/1968 Surow1tz.....161/156 X 2,774,128 12/1956 Secrist ..161/150X PATENTEUFEBZOIUYZ,

SHEET 10F I FIG.

E D U G STITCHING NEEDLE FIG. 3

INVENTOR. SAMUEL M. SCHWARTZ his ATTORNEYS PMENTED FEBE 0 I375 sum 20F2FIG. 8

INVENTOR SAMUEL M. SCHWARTZ By B .Qnm

M WY his ATTORNEYS ABSORBENT STRETCI-IABLE FABRIC BACKGROUND OF THEINVENTION Stretchable fabrics have been available on the market for anumber of years and have been used for diapers. Diapers formed withstretchable fabrics are better fitting, more comfortable, lessconstricting and relatively free from sagging in comparison to diapersmade from non-stretchable fabrics. Stretchable fabrics are availablehaving varying degrees of absorbency and, generally speaking, the moreabsorbent fabrics have been chosen for diaper construction. Where asingle layer of stretchable fabric having a hydrophilic(water-absorbent) character is used, it suffers from the disadvantagefound in many non-stretchable diapers, namely, body fluids are retainedin contact with the wearers skin, thereby encouraging the development ofdiaper rash.

Diapers have recently been developed which employ a combination ofhydrophilic and hydrophobic (waterrepellent) materials. In someinstances, a layer of hydrophobic material is provided on theskin-contacting side of the diaper and a hydrophilic layer on theopposite side, so that fluids are passed through the hydrophobic andinto the hydrophilic layer, keeping the wearer relatively dry. Suchconstructions are disclosed, for example, in U.S. Pat. Nos. 3,180,335,3,295,526, and 2,905,176.

While multi-layer diapers of the type described above have a number ofadvantages, they have also developed many problems. For example, in atypical construction where the different layers are bonded or laminatedtogether with adhesives, the bond weakens after several uses andwashings, often causing the layers to separate. Where the separation ofthe layers is complete the diaper becomes useless. If separation ispartial, an air pocket forms between the separated layers and preventsfluids from transferring efficiently to the absorbent layer. Further,the resin normally used to bond the layers together is non-porous andhydrophobic and impedes the transfer of fluids from one layer toanother.

To compensate for the reduced transferability of fluids in such diapers,some manufacturers have increased the size of the pores in theskin-contacting layer The larger pores, however, have the defect thatthey allow the fluids to return through the hydrophobic layer and comeinto contact with the wearers skin.

Due to the fact that the multi-layer diaper constructions are made frommultiple layers of different materials with different properties, eachlayer often shrinks a different amount upon laundering, causing aseparation or buckling of the layers. As explained above, separation ofthe layers may impede transfer of fluids from one layer to another, ormake the diaper useless. In addition, buckling may make the diaperuncomfortable to wear.

Additional problems arise with multi-layer diapers in the cutting andprocessing steps of manufacture. When numerous, loose layers are piledone on top of another, the cutting and sewing processes are difficult,and the results are not uniform. Furthermore, if the fabrics areknitted, the edges of such layers often curl, making the binding processmore difficult.

SUMMARY OF THE INVENTION The fabric of the present invention overcomesthe aforementioned problems by providing an absorbent shrinkable web ofhydrophilic material encased in a warp knitted fabric of relativelynon-shrinkable yarn. The yarn is formed into a series of interconnectedloop chains which are knitted thrbugh the web in the manner, forexample, of a tricot or half-tricot stitch. After the web has beenencased in the yarn, the fabric is subjected to heat and moisture,causing the web to undergo substantial shrinking relative to the yarn.As a result, the loop chains of yarn loosen, permitting limitedstretching of the fabric.

When used as a diaper, the absorbent shrinkable web is comprised of alayer of shrinkable hydrophilic material and at least one layer of ashrinkable hydrophobic material. A diaper having this structure permitsimmediate transfer of fluid through the hydrophobic layer and into thehydrophilic layer, tending to keep the wearers skin dry.

The improved fabric constructions of the present invention are easier tomanufacture and process than those disclosed in the prior art, are morecomfortable to wear, and are less costly to produce. When utilized as amulti-layer diaper, the improved fabric has the additional advantages ofminimum differential shrinkage and prevention of layer separation andbonding impediments. Such diaper does not allow fluids to return to thewearers skin and does not contain any irritating or harmful chemicals.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view incross-section of the fabric of the present invention;

FIG. 2 is a schematic view of a stitching apparatus, shown performingthe operation of encasing the absorbent, shrinkable web in a warpknitted fabric;

FIG. 3 is an isometric view in cross-section of a twolayer embodiment ofthe present invention;

FIG. 4 illustrates a diaper made in accordance with the invention;

FIGS. 5 and 6 show variations in the structure of diapers made inaccordance with the present invention;

FIG. 7 is an isometric view in cross-section of a three-layer embodimentof the invention; and

FIG. 8 illustrates a swimsuit garment employing the fabric of thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings indetail, FIG. 1 illustrates one embodiment of the fabric of the presentinvention. A continuous web 10 of a shrinkable hydrophilic material isencased in a warp knitted fabric of relatively non-shrinkable yarn 12forming fabric 11. The fabric 11 becomes stretchable after it has beensubjected to heat and moisture and the web 10 has shrunk significantlymore than the yarn 12. A normal laundering cycle provides significantheat and moisture for shrinkage of the web 10.

By a web of a hydrophilic material I mean a web of material that iswater-absorbent. By hydrophobic yarn I mean yarn that iswater-repellent.

After the web has been encased in the yarn 12, and the fabric has beencut to its required size, but before it has been shrunk forstretchability, the edges of the fabric 11 preferably are covered by aborder 13 which is stitched into place by conventional sewing machines(not shown). The border 13 prevents the yarn 12 from unraveling andpresents a pleasing and finished appearance to the fabric 11.

The absorbent layer 10 is preferably of rayon but it can be of anyabsorbent material or fabric, such as cotton, wood pulp, or cellulose.Where rayon is used for the hydrophilic layer 10, it may be preferableto blend with it a portion of another material, for example,polyvinylchloride fibers, in order to give the layer more durability.Upon being subjected to heat, the polyvinylchloride fibers melt and bondtogether the rayon fibers, holding them in place. A construction wherebythe hydrophilic layer 10 contains 85 percent rayon and 15 percentpolyvinylchloride fibers has produced a product having excellentdurability, although it is to be understood that these percentages ofrayon and polyvinylchloride are not critical. Since the reduction of theweight of the rayon content has the tendency to reduce the absorbency ofthe layer 10, it is preferable to use less than 15 percentpolyvinylchloride fibers in the construction. It is also to beunderstood that fibers of another material having the desired durabilityproperties, for example, polyvinyl acetate, can be used in place ofpolyvinylchloride.

The material forming the web 10 can be spun or unspun, pressed orunpressed, knitted or unknitted,

woven or unwoven.

The yarn 12 which is used to encase the web 10, can be of any suitablerelatively non-shrinkable material and preferably is hydrophobic.Suitable materials include spun or unspun yarns of a polyester, nylonfilaments, an acrylic, polypropylene, and the like. Such yarn 12,however, has to have the characteristic that it will not shrinksubstantially upon being subjected to normal washing and drying cycles,or will not shrink more than 50 percent relative to the shrinkage of theweb 10.

The material used for the border 13 can be any suitable material, butpreferably it is to be hydrophobic and relatively non-shrinkable. It isunderstood that the border 13 is not a required feature of the inventionand it is possible to prepare a suitable absorbent stretchable fabric 11without it.

FIG. 2 illustrates the stitching process whereby the web 10 is encasedin a warp knitted fabric of yarn 12. The stitching machine shown is aMaliwatt' machine which utilizes the Malimo technique of forming fabricat high speeds. Mali machines and the textilefabrics made therewith aredisclosed in U.S. Pat. Nos. 2,890,579, 3,030,786, and 3,279,221. It isto be understood that any equivalent machine, for example, the Arachnemachine or another Mali machine, can be utilized for preparing thefabric of the present invention.

In the stitching process, the web 10 is conveyed by a supportarrangement to the stitching area of the machine where it is compactedand encased by the stitching yarn 12 to form a firm fabric 21. Either atricot or half-tricot stitch which form interconnected loop chains ofyarn can be used.

In the present invention, seven to 14 stitches per inch are preferred.Fewer stitches per inch increase the fluffiness of the construction butdecrease its durability. A greater number of stitches per inch increasethe durability of the construction, but decrease its absorbability.Where the stitches are on the order of seven per inch, it is preferableto use a material for the web 10 which has relatively long fibers inorder to minimize losses in laundering. For example, a constructionhaving a warp knitted fabric 21 of 7 stitches per inch and ahydrophillic layer 10 comprised of rayon with fibers approximately 3 kinches in length has produced a product with excellent durability Afterthe stitching process has been completed, the fabric 11 is cut to thedesired size and a border 13 is sewn around its circumference (asheretofore described). Prior to cutting, the fabric 11 is preferablyscoured and dried, and the yarn 12 is heat set, in the manner describedlater in relation to FIG. 3.

If it is desired to make the linear dimension of the hydrophilic web 10more stable before stitching, it can be pressed by needle punching. Theneedle punching substantially reduces the thickness of the web 10. Theseparate step of pressing is not necessary, however, as the stitchingmachines will compress the web 10 during the stitching process.

For stretchability, the fabric 11 is subjected to at least one normalwashing and drying cycle. In practice the fabric 1 1 will shrinkapproximately 90 percent of its total shrinkage capability during itsfirst laundering cycle. Experiments have shown that the web 10 willshrink approximately 15-25 percent while the yarn 12 will shrinkapproximately 5-10 percent. Because the web 10 shrinks more than theyarn 12, the shrinkage of the web 10 contracts the loops 22 (FIG. 1) ofyarn 12 causing the loops 22 to become more rounded. When tension isapplied to the shrunk fabric 11, the loops 22 flatten to at least theiroriginal position allowing the fabric 11 to stretch. When the tension issubsequently released, the loops 22 return to their after-shrinkagerounded condition.

FIG. 3 illustrates an embodiment of the present invention where thefabric 11 is utilized as an improved diaper. A hydrophobic layer 14 isplaced in contact with a hydrophilic layer 15 and the two layers 14 and15 are encased in a warp knitted fabric of hydrophobic yarn 12.

The hydrophilic layer 15 and the hydrophobic yarn 12 are of the samematerials and constructions as described above.

The hydrophobic layer 14 can be of any hydrophobic material, such aspolyethylene, polypropylene an acrylic, 'nylon, or any polyester, butpreferably it is Reemay, a product of DuPont, or a spun polyester yarn.The Reemay material used in this embodiment is comprised of continuouspolyester fibers (approximately percent) mixed with a high-shrinkbiconstituent yarn (approximately 20 percent) and is vibrated fromspinerettes and spun and bonded into a thin, easily workable web.

The stitching process whereby the layers 14 and 15 are intimately andpermanently bound together is the same as that described above inreference to FIGS. 1 and 2.

The stitching process can be utilized irrespective of whether thematerials forming the layers 14 and are spun or unspun, pressed orunpressed, knitted or unknitted, woven or unwoven. For example, anunwoven, unpressed web or bat of rayon can be stitched together with anunspun, unbonded, web or bat of polyester to form the diaperconstruction.

Although it is possible to construct the present invention using anunspun, unbonded hydrophobic layer 14, it is preferable to use apreformed material, for example, Reemay or a spun polyester yarn, asdescribed above.

Also, although the fabrics used in layers 14 and 15 can be of anyknitted or woven construction, the fabrics are preferably made usingnon-woven fabrics. Non-woven fabrics permit a closer contact between twoadjacent layers, thus enhancing the transferability of fluids from onelayer to the other.

Besides permanently binding the two layers together, the stitchingprocess also provides the necessary holes in the hydrophobic layer 14which permit fluids to pass through the layer 14 and into thehydrophilic layer 15. The holes are large enough so that the fluids canbe forced through them, by the force imparted to the fluids by thewearer and by the pressure exerted by the body of the wearer against thediaper, and yet small enough so that the fluids cannot return throughthem by liquid flow.

The above-described embodiment of the invention can be used either as apermanent or a disposable diaper. It may be preferable in a disposableconstruction, however, to use a material which is less costly than rayonfor the hydrophilic layer 15. Such materials can be, for example,cotton, wood pulp, cellulose wadding, felt, and other forms of nonwovenmaterials.

After the stitching process has been completed, the construction is cutto the desired size and a border 13 of a hydrophobic material is sewnaround the circumference of such construction, as described above. Inaddition to enhancing the appearance of the construction 7 andpreventing the yarn 12 from unraveling, the border 13 in the multi-layerdiaper construction prevents fluids absorbed in the hydrophilic layer 15from seeping around the edges of the hydrophobic layer 14 and cominginto contact with the wearers skin.

For stretchability, the two-layer embodiment is laundered and the twolayers shrunk as described above regarding FIG. 1. For a constructionwherein the hydrophilic layer 15 is a rayon web blended with 15 percentpolyvinylchloride fibers, the hydrophobic layer 14 is Reemay, and thehydrophobic yarn 12 is polyester, the following shrinkage results wereachieved when each of the three items were subjected to boiling water (b212F) and dried at the same temperature:

Rayon web: 19 percent shrinkage in warp or machine direction; 23 percentshrinkage in the crossmachine direction.

Reemay: 3-5 percent shrinkage.

Polyester Yarn: 8-10 percent shrinkage.

Although the Reemay only shrinks on the order of onequarter of the rayonweb 15, the substantial decrease in cross-sectional area of the rayonweb 15 within the loops 22 of yarn 12 provides the necessary shrinkagefor stretchability.

For the above test, a temperature of 2 l 2F was used because it is theapproximate temperature used in the washers and dryers of mostcommercial laundering services. Typical household washers and dryers useslightly lower temperatures, normally within the range of 200F. j'

Temperatures in excess of 300F should not be used in laundering andshrinking the fabric 11 because these temperatures might cause thepolyester yarn 12 to shrink an undesirable amount thereby ruining thestretchability characteristic of the fabric 1 1.

The fabric 11 is preferably laundered after completion but beforemarketing to wash out any dirt acquired during manufacture, any tintingused for internal identification purposes, and any sizing. Thislaundering step does not have any significant effect on shrinkage,because the fabric 11 is washed in lukewarm water, mounted on a rigidframe while passing through a drying oven, and dried at a temperature onthe order of 200F. The fabric 11 can be bleached or dyed at the sametime it is laundered.

Where the yarn 12 is polyester or a similar material, the initiallaundering step also has the advantage that it can be utilized toheat-set the yarn 12 and hinder its subsequent shrinkage. After thefabric 11 is washed, but before it enters the drying oven, it preferablyis passed through an area where the temperatures are in the range of250280F, sufficient to heat-set the yarn 12. The fabric 11 is to remainin this area only long enough to set the polyester yarn, the moistureretained in the web 15 prevents it from reaching its shrinkagetemperature.

The embodiment shown in FIG. 3 permits instantaneous transfer of fluidsthrough the hydrophobic layer 14 with no back-leakage and provides acomfortable, stretchable diaper. Unlike diapers known in the art, thelayers 14 and 15 of this construction cannot separate causing decreasedtransferability and uncomfortable buckling. Also, it is not necessary touse bonding agents which impede the transferability of known diapers.Furthermore, since the present invention is, in effect, a one-layerconstruction, problems relating to differential shrinkage, and cuttingand sewing of numerous loose layers are eliminated.

FIGS. 4-6 illustrate various embodiments of the present invention.

FIG. 4 illustrates a conventional rectangular shaped fabric 11 withrounded corners and is the preferred shape for the present inventionwhen used as a diaper.

FIG. 5 illustrates a diaper construction of the twolayer embodimentwherein the hydrophilic layer 15 is smaller in surface area than thehydrophobic layer 14. This embodiment permits greater ease of handlingand fastening of the diaper around the wearer.

The embodiment shown in FIG. 5 is slightly more difficult to manufacturethan any of the other embodiments as it requires accurately spacingseparate strips of the hydrophilic material 15 on the supportarrangement 20 (FIG. 2). The fabric making machines generally produce afabric 21 which is much wider than the width of a single diaper, andtherefore, numerous strips of the hydrophilic material 15 must be placedon a layer of the hydrophobic material 14 for stitching.

It is also possible for two of the opposite edges 25 and 26 of thediaper construction to be concave to facilitate a better fit on thewearer. Such an embodiment is shown in FIG. 6. The dotted lines 30 and31 on FIG. illustrate the concave edge feature on a diaper where thehydrophilic layer is smaller in width than the hydrophobic layer 14.

FIG. 7 illustrates another embodiment of the present invention in whicha second layer 35 of hydrophobic material is placed in contact with thehydrophilic layer 15, sandwiching the layer 15 between two hydrophobiclayers 14 and 35. The second hydrophobic layer 35 can be, for example,another layer of DuPont's Reemay, a layer of plastic similar to thematerial used in infant rubber pants, or a layer of any otherhydrophobic material. When used as a diaper, this three-layerconstruction eliminates the need for protective pants.

The present invention is not limited to diaper constructions, but can beused in numerous ways and can be employed for making many types ofgarments. The fabric 11 can be utilized, for example, as an absorbentpad or as a swimsuit.

When used as an absorbent pad, the fabric 11 would preferably besubstantially rectangular in shape (similar to FIG. 4). Such pads haveuses, for example, as bed pads under people who are unable to controltheir body functions. If it is desired to transfer fluids away fromcontact with an object or person, then the two and three-layerembodiments shown in FIGS. 3 and 7, respectively, can be utilized.

When the present invention is used as a fabric for a swimsuit 40, asshown in FIG. 8, preferably the twolayer embodiment (FIG. 3) will beemployed. The hydrophobic layer 14 next to the wearers skin willtransfer the water away from the wearers skin and into the adjacenthydrophilic layer 15. The hydrophilic layer 15 preferably would containa greater percentage of polyvinylchloride filaments than in theaforementioned constructions in order to make the layer 15 lessabsorbent and thus able to transfer the water to its outside surfacemore readily so that it can be evaporated by the air. This constructionwould prevent the wearer from experiencing the cooling sensationexperienced when one first steps out of a body of water and the waterstill contained in the swimming garment begins to evaporate drawing heataway from one 5 body.

Whenever the two-layer embodiment (FIG. 3) of the present invention isused as a diaper or a pad, preferably it will be necessary to mark oneside of the construction in some manner so that the user will not getconfused as to which side to place next to the wearer's skin and whichside to place away from the wearer. Such markings can be accomplished,for example, by dyeing or tinting the hydrophilic layer 15, or bymarking one side with a permanent, colored line. The inclusion of a fewparts per thousand of a colored fiber into the web of the hydrophiliclayer 15 would tint such layer. Placing a brush or dye marker (notshown) on the stitching machine (shown in FIG. 2) immediately below thestitching needles so that it comes in contact.

were conducted. The results of these tests are provided in the followingtable:

5 RELATIVE WETNESS 0F DIAPER SURFACES (Dry Fabric Surface 0) TimeIntervals (minutes) After Wetting Fabric The three diapers used in thecomparative tests with the present construction were all purchased onthe open market. The Three-Layer Disposable Diaper was marketed asPampers (manufactured by Proctor & Gamble Co.) and was comprised of apad formed from piles of creped cellulose wadding and a porous,hydrophobic top sheet both layers attached to a back sheet of awaterproof material. This construction is covered by the Duncan et al.patent, U.S. Pat. No. 3,180,335.

The Conventional Cotton Gauze Diaper was a prefolded Curity diaper(manufactured by Kendall), comprised of layers of cotton gauze.

The Diaper with Hydrophobic Yarns" was marketed as Babycare(manufactured by Riegel Textile Corp.) and was comprised of a layer ofinterwoven hydrophobic and hydrophilic yarns (woven so that hydrophobicfibers predominated the outside surface of such layer) and numerouslayers of cotton gauze forming an absorbent pad. This construction iscovered by the Holliday et al. patent, U.S. Pat. No. 3,113,570.

The four diapers were laid side by side on a plastic film surface andall were wetted with 50 milliliters of tap water. All of the water waspoured on one spot of each diaper and that same spot was used for thesubsequent measurements of wetness.

A Crystalab Ionimeter (Model CT-2I) water conductivity indicator wasutilized for the fabric wetness tests. This instrument is normally usedto test the purity of water by measuring the electrical conductivity ofthe water and the parts per million of salt in the water. The instrumentwas modified to measure the wetness of the diaper by extending theelectrode contact points by suitable wiring and housing the two ends ofthe wire in a plastic assembly. The contact points were two brassscrewheads, fifteen thirty-seconds of an inch in diameter. The plasticprobe containing the two contact points weighed 199 grams and exerted apressure of 1.27 pounds per square inch on the fabric surfaces. Suchpressure is of a magnitude comparable to body pressures exerted on adiaper by a baby.

The figures in the above table were read from the logarithmic arc-type"parts per million scale on the Ionimeter and are an index of therelative wetness of the fabric surface. The dryer the surface, the lowerthe electrical conductivity and thus the lower the measurement of theparts per million of salt'in the water.

Referring to the above table, the results show that the figurescorresponding to the Absorbent Stretchable Fabric were consistently andconsiderably lower than those of the other three diapers. The surface ofthe Absorbent Stretchable Fabric was thus substantially dryer at the endof each of the six measured time intervals than those of the others.

The figures in the table are also directly proportional. This means thatat the end of minutes, the Three-Layer Disposable Diaper was four timesas wet as the Absorbent Stretchable Fabric, the Conventional CottonGauze Diaper was 2.5 times as wet as the Absorbent Stretchable Fabric,and the Diaper with Hydrophobic Yarns was 4.5 times as wet as theAbsorbent Stretchable Fabric.

1 claim:

1. An absorbent stretchable diaper comprising a layer of a hydrophilicmaterial, at least one layer of a hydrophobic material, andsubstantially non-shrinkable yarn, the hydrophilic and hydrophobiclayers being maintained in contact with each other by a series ofinterconnected loop chains of the yarn knitted through the layers toencase the layers in a warp knitted fabric of the yarn.

2. An absorbent diaper as defined in claim 1 wherein the fabric has aborder therearound to enclose the edges of the fabric.

3. An absorbent diaper as defined in claim 2 wherein the border is ahydrophobic material.

4. An absorbent diaper as defined in claim 1 wherein the yarn ishydrophobic.

5. An absorbent diaper as defined in claim 4 wherein the yarn is nylon.

6. An absorbent diaper as defined in claim 4 wherein the yarn is apolyester.

7. An absorbent diaper as defined in claim 4 wherein the yarn is anacrylic.

8. An absorbent diaper as defined in claim 1 wherein the hydrophiliclayer is smaller in surface area than the hydrophobic layer.

9. An absorbent diaper as defined in claim 1 wherein the hydrophobicmaterial is a non-woven fabric.

10. An absorbent diaper as defined in claim 1 wherein the hydrophilicmaterial is a web of rayon.

11. An absorbent diaper as defined in claim 10 wherein the hydrophilicmaterial contains at least 1% polyvinylchloride fibers.

12. An absorbent diaper as defined in claim 1 wherein the hydrophobicmaterial is nylon.

13. An absorbent diaper as defined in claim 1 wherein the hydrophobicmaterial is a polyester.

14. An absorbent diaper as defined in claim 1 wherein the hydrophobicmaterial is an acrylic.

15. An absorbent diaper as defined in claim 1 wherein the hydrophiliclayer and the yarn have the characteristics that the hydrophilic layerwill shrink at least 10% more than the yarn.

16. An absorbent diaper as defined in claim 1 wherein the diaper iscomprised of two layers of a hydrophobic material, the hydrophobiclayers being placed on opposite sides of the hydrophilic layer tosandwich the hydrophilic layer therebetween.

1. An absorbent stretchable diaper comprising a layer of a hydrophilicmaterial, at least one layer of a hydrophobic material, andsubstantially non-shrinkable yarn, the hydrophilic and hydrophobiclayers being maintained in contact with each other by a series ofinterconnected loop chains of the yarn knitted through the layers toencase the layers in a warp knitted fabric of the yarn.
 2. An absorbentdiaper as defined in claim 1 wherein the fabric has a border therearoundto enclose the edges of the fabric.
 3. An absorbent diaper as defined inclaim 2 wherein the border is a hydrophobic material.
 4. An absorbentdiaper as defined in claim 1 wherein the yarn is hydrophobic.
 5. Anabsorbent diaper as defined in claim 4 wherein the yarn is nylon.
 6. Anabsorbent diaper as defined in claim 4 wherein the yarn is a polyester.7. An absorbent diaper as defined in claim 4 wherein the yarn is anacrylic.
 8. An absorbent diaper as defined in claim 1 wherein thehydrophilic layer is smaller in surface area than the hydrophobic layer.9. An absorbent diaper as defined in claim 1 wherein the hydrophobicmaterial is a non-woven fabric.
 10. An absorbent diaper as defined inclaim 1 wherein the hydrophilic material is a web of rayon.
 11. Anabsorbent diaper as defined in claim 10 wherein the hydrophilic materialcontains at least 1% polyvinylchloride fibers.
 12. An absorbent diaperas defined in claim 1 wherein the hydrophobic material is nylon.
 13. Anabsorbent diaper as defined in claim 1 wherein the hydrophobic materialis a polyester.
 14. An absorbent diaper as defined in claim 1 whereinthe hydrophobic material is an acrylic.
 15. An absorbent diaper asdefined in claim 1 wherein the hydrophilic layer and the yarn have thecharacteristics that the hydrophilic layer will shrink at least 10% morethan the yarn.